Configurable protective cover, method of making and method of using

ABSTRACT

Disclosed herein is a cover for an electronic device that comprises a plurality of medallions extending outwardly from a flexible base sheet. The base sheet is adapted to conform to at least a portion of the outer surface of the device, so that the medallions are located at impact regions such as the corners, edges and around the screen. The medallions are adapted to maintain the device in spaced relation from an impact surface.

CROSS REFERENCE TO RELATED CASES

Priority under 35 U.S.C. §119(e) is hereby claimed to commonly-owned andco-pending U.S. Provisional Application No. 61/509,105, which was filedon Jul. 18, 2011, and which is incorporated herein by reference in itsentirety.

TECHNICAL FIELD

The present invention relates generally to configurable covers designedto protect sensitive items from damage and/or to provide an exteriorsurface that is comfortable to touch.

BACKGROUND

Protective cases for sensitive equipment, devices or instruments areoften designed with padding on the interior or exterior, or both. Manytimes the padding is formed of continuous sheets of protectivematerials, such as neoprenes, foams and/or laminated materials, and thelike. Such cases often do not offer sufficient protection from impact,vibration, and the like. Protection for the devices may be improved byusing thicker materials, but increasing the thickness may not bedesirable due to the added bulk or weight. Moreover, increased weightand bulk may be undesirable for streamlined electronic devices, forwhich users usually pay a premium in order to obtain slim and/orlightweight products.

Many electronic devices have a screen interface used to displayinformation to users, so it is necessary to expose the screen duringuse. However, screen interfaces are known to be delicate, tending tobreak easily when dropped or otherwise impacted.

Portable electronic devices, such as laptop computers, or medicalequipment, also have screen interfaces, and to protect the screeninterface, such devices often include a hinged protective cover thatprovides some protection from dropping or impact, when not in use.However, many cell phones, media devices, and tablet-style computers ornetbooks do not include such covers. Therefore, a screen or edge impactcan easily cause severe damage to the screen and/or device. In addition,some devices, such as iPad devices, are very thin and delicate, whichexacerbates their ability to withstand an impact. As a result, manycompanies now manufacture covers, cases and shells that can be purchasedseparately from the device s, which tend to fall into a few differentcategories.

One type of case is a rigid plastic shell, which may include internal orexternal padding, such as rubber or silicone. These types of shells aremade for specific device sizes and configurations. In addition, rigidshells, even with some soft added elements, may not protect well againsta drop of the face or open screen

Another type of case is a soft “skin,” generally made of rubber,silicone or other thermoplastic elastomeric (“TPE”) material. Like rigidplastic shells, skins are made for specific device sizes andconfigurations, and therefore cannot be used for “next-generation”devices. Other disadvantages are that they are generally thin, andtherefore provide only minor impact protection and mostly scratchprotection. Once again they are not generally able to protect the devicefrom a significant drop on the screen side

There is a need for an improved case for sensitive equipment, devices orinstruments.

SUMMARY

The present disclosure is directed to a cover for an electronic device,comprising a flexible base sheet having a thickness. The base sheet isadapted to stretch and conform to at least a portion of the outersurface of the device. The base sheet comprises a plurality of spacedapart medallions having a thickness greater than that of the base sheet.The plurality of medallions extend outwardly from the base sheet, tomaintain the device in spaced relation from a surface. The medallionsmay be disposed on the device such that they correspond to impactpoints, such as corners, edges and/or around the screen regions.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the Figures, the features and advantages of the presentdisclosure will be apparent from the following more particulardescription of exemplary embodiments, as illustrated in the accompanyingdrawings, in which like reference characters refer to the same partsthroughout the different views. The drawings are not necessarily toscale, emphasis instead being placed upon illustrating the principles ofthe disclosure.

FIG. 1 is a perspective front view of a media device with an exemplaryprotective cover according to the present disclosure, disposed on thedevice;

FIG. 2 is a perspective back view of the media device shown in FIG. 1;

FIG. 3 is an exploded top view of the front portion of the cover and thedevice shown in FIG. 1;

FIG. 4 is a top view of the front portion of the cover and device ofFIG. 1;

FIG. 5 is a perspective view of the front portion of the cover anddevice of FIG. 1, with the device shown in phantom underneath the cover;

FIG. 6 is a perspective view of the front portion of the cover anddevice of FIG. 1, with the device shown in phantom underneath the cover,showing the process of folding the cover tabs onto the back of thedevice;

FIGS. 7 is a back view of the device in FIG. 1, showing the frontportion of the cover fully assembled onto the device of FIG. 1, againwith the device shown in phantom underneath the cover;

FIG. 8 is an exploded back view of the back portion of the cover and thedevice shown in FIG. 7, with the front cover fully assembled onto thedevice;

FIG. 9 is a cross-sectional view of the device shown in FIG. 6, throughline 9-9;

FIG. 10 is a cross-sectional view through one embodiment of the bezelregion of the front cover;

FIG. 11 is a cross-sectional view through an alternative embodiment ofthe bezel region of the front cover;

FIG. 12 is a cross-sectional view through an alternative embodiment ofthe bezel region of the front cover;

FIG. 13 is a cross-sectional view of one embodiment of the back cover;

FIG. 14 is a cross-sectional view through another embodiment of the backcover;

FIG. 15 perspective front view of a laptop computer with anotherexemplary protective cover according to the present disclosure, disposedon the device;

FIG. 16 is a bottom view of the media device of FIG. 15; and

FIG. 17 is a cross-sectional view of the device shown in FIG. 15,through line 17-17.

DETAILED DESCRIPTION

The present disclosure is directed to “stick-on” covers that can beremovably applied to electronic devices such as media devices, smartphones, netbooks, notebooks, iPads, iPhones, MacAir, laptop computers,television screens, gaming devices, and the like. While the presentdisclosure has been described for protective covers for electronicdevices, the disclosure can also be applied to any type of protectivecovers. The covers of the present disclosure include those that coverthe entire body of electronic device, or portions thereof. For ease ofillustration, the term “cover” will be used interchangeably herein tomean a cover for only portions of the device, or for substantially theentire device. The present covers include several features that combinereduced weight, reduced bulk, and improved aesthetics, while providingimproved protection for the device. The improved cases may be used forsensitive equipment, devices or instruments, are lightweight and provideimproved impact protection, particularly for exposed screen or “in-use”devices. The present cases are not specific to one device size, butinstead can accommodate a range of device sizes.

FIGS. 1-2 show front and back perspective views of a media device atleast partially covered in an exemplary cover according to the presentdisclosure. The present cover comprises separable front and back covers30,40.

FIG. 3 shows an exploded view of the device 20, front cover 30 and backcover 40. As used herein, the assembly of the front cover 30 and device20 is referred herein to as 10 a, and the assembly of the back cover 40and the device 20 is referred to herein as 10 b.

As shown in FIG. 4, front cover 30 comprises a base sheet 112 and ascreen cover region 140 (hereinafter “screen cover”) sized anddimensioned to accommodate the front screen 192 of device 20. At leastone impact-absorbing medallion 120 (“medallion”) is disposed adjacent toand between the base sheet 112 and the screen cover region 140, with anoptional raised region 125 in the center, and an optional flange 123extending outwardly from the raised region.

An optional bezel medallion 150 (hereinafter “bezel”) is disposedadjacent to and between the base sheet 112 and the screen cover region140, with an optional raised region 155 in the center, and an optionalflange 160 extending outwardly from the raised region.

At least one impact-absorbing side medallion 130 is disposed adjacent tothe base sheet 112, with an optional raised region 133 in the center,and an optional flange 134 extending outwardly from the raised region.

Unlike other screen protectors, the present cover 30 extends beyond thescreen 192 of the device, to cover function devices as well, and wrapsaround the device, folding onto the back side of the device. Therelatively large surface area of the cover improves the adhesion of thesmaller medallions, thereby minimizing or eliminating the tendency topeel away, were they not held down by the film.

The base sheet is adapted to conform to at least a portion of the outersurface of the device, so that the medallions are located at impactregions such as the corners, edges and around the screen. The medallionsare adapted to maintain the device in spaced relation from an impactsurface.

FIG. 10 shows base sheet 112 in cross-section, with an optional layer ofa pressure sensitive adhesive (“PSA”) 174 disposed on the surface of thescreen cover 140, facing the screen, and on the surface of base sheet112, facing the body of the device. Optionally, the PSA may also bedisposed underneath and adjacent to the medallions 120, 130. SuitablePSAs for the PSA disposed under the screen cover 140 are those thatwould be well known to manufacturers of non-impact protecting screenprotecting films. Suitable PSAs for the PSA disposed on base sheet 112include those that can bond to the body material, such as plastic,metal, and the like, and optionally that are permanently or temporarilyrepositionable, to allow a user to reposition the cover, or to removethe cover and apply it to a new device. Suitable PSAs for the optionalPSA disposed underneath the medallion 120 include the same materials asthose for the base sheet, provided that the PSA can also withstand anyprocessing to which it may be subjected, such as the comolding describedbelow. The first, second and third PSAs may be the same, provided thatthe PSA meets the requirements needed for the screen area. Those ofskill in the art will recognize that other methods maybe used to attachmedallions to the device, other than a PSA, such as magnetic attachment,a “clinging film” that adheres by cohesive force, Velcro, suction,static, and the like.

In the present embodiment, the optional raised region protrudes throughan opening defined by base sheet 112 and screen cover 140 such that thesheet 112 and cover 140 overlap the flange 123 of the medallions 120,130.

The thickness of the raised regions of the medallions and bezel can beselected to provide sufficient impact protection, without impeding theuser's fingers. Also optionally, the thickness of the raised regions canbe graduated such that the thickest portion is in the center of themedallion, and the thinnest portion is in the flange. Alternatively, themedallions can comprise a uniform thickness (i.e., no raised region) andwhen the raised region is omitted, the base sheet would overlap the edgeof the medallion.

The medallions 120,130 may include optional openings corresponding tofunctional devices on the phone, such as the speaker and microphone,such that they are exposed for use, and the case does not interfere withthe function of the device. As shown in the present embodiment, thecover comprises various openings that correspond to functional devicessuch as the device speaker, microphone, camera, and the like.Alternatively, the function devices may be protected by a film extendingover the opening, formed from a material that does not interferencewith, for example, the speaker or the camera.

Suitable materials for base sheets include those that would be suitablefor use as a screen protector for an electronic device such as a smartphone, such as a polyurethane film or sheet. If desired, the materialused for the screen cover 40 can be different than the base sheet 112,and the material used in for the base sheet can be flexible or stretchy,to accommodate wrapping around the corners and/or sides of the devices.

A variety of techniques may be used to form the front cover. That is,the medallions 120, 130 and/or the bezel 150, and the base sheet 112 andcover 140 may be formed separately, and bonded, welded and/or gluedtogether. Those of skill in the art will recognize that a variety oftechniques and methods may be used to bond the medallions and sheettogether including, but not limited to, chemical, mechanical, thermalbonds. Examples include bonding using an adhesive or cement, or sonicwelding.

In the present embodiment, as shown in FIG. 10, the impact-absorbingmedallions 120, 130 and base sheets 112, 140 are formed separately, andbonded together at interface region 115. Those of skill in the art willrecognize that a variety of techniques and methods may be used to bondthe medallions and sheet together including, but not limited to,chemical, mechanical, thermal bonds. Examples include bonding using anadhesive or cement, or sonic welding.

In an alternative embodiment, as shown in FIG. 11, the base sheet doesnot include an opening through which the medallions 120,130 and/or bezel150 protrude and, instead, the medallions 120,130 and bezel 150 aredisposed on the upper surface of the base sheet 112. As in the previousalternative embodiment, the medallions 120,130 and bezel 150 are formedseparately from the base sheet 140, and bonded together at interface115, using the same techniques mentioned above, and methods disclosed inthe publications listed above. If desired or necessary, an intermediatelayer, such as a PSA 174, may be disposed between the lower surface ofthe medallions 120,130 and/or bezel 150, to facilitate bondingtherebetween.

In another alternative embodiment, as shown in FIG. 12, the base sheet112 does not overlap the medallions 120,130 and/or bezel 150. Instead,the base sheet 112 and medallions 120,130 and/or bezel 150 have acontiguous interface at region 119, such as may be produced whenco-molded, using the same techniques mentioned above, and methodsdisclosed in the publications listed above.

Those of skill in the art will recognize that a variety of techniquesand methods may be used to bond the medallions and sheet togetherincluding, but not limited to, chemical, mechanical, thermal bonds.Examples include bonding using an adhesive or cement, or sonic welding.

FIG. 13 shows a cross-section of the back cover 40, which comprises aplurality of spaced apart impact absorbing medallions 180 disposed on abase sheet 112, which may comprise the same material as the front coverbase sheet. The back cover may comprise the same construction techniquesas the front cover. That is, the medallions 180 and base sheet 112 maybe formed separately, and bonded, welded and/or glued together.

FIGS. 15-17 show a laptop device 200 with a base 210 and a hinged cover220, with an exemplary cover 240 according to the present disclosure.The top surface of the base 210 comprises at least one medallion 250disposed adjacent to the keyboard, which spaces the cover 220 from thebase 210, and minimizes impact from closing, during a fall, and thelike. The bottom surface of the base comprises a plurality of spacedapart medallions 180, similar to the back cover in the previousembodiment. The medallions 180 and 250 are supported on a base sheet112, as in the previous embodiment, and may be constructed using thesame materials and techniques as in the previous embodiment.

The medallions and bezels according to any of the embodiments herein maybe formed from a variety of materials including, but not limited to,polymeric materials, including foamed polymeric materials, compositematerials, and the like. One exemplary material is a rate dependent foamavailable from Rogers Corporation (Rogers, Conn.) under the product namePORON XRD®. Other suitable materials and methods of making themedallions and/or covers are disclosed in U.S. Publication Nos.2007/0261274, 2008/003614, 2009/0255625, which are incorporated hereinby reference in its entirety. In some embodiments, the materials fromwhich the medallions are made may comprise a cushioning material 190 andan extensible outer layer 195, such as a TPE film.

The present covers are also flexible and conformable and, as a result,the covers can conform to contoured surfaces, such as the slightlycurved surfaces of iPhones and iPads; to relatively sharp edges, such asthe edges of iPad and MacAir devices; and can wrap around side edges,such as the sides of iPhone devices and many laptop computers. Thepresent covers are also configurable, i.e., they can be configured formultiple devices, eliminating the need to manufacture device-specificcovers.

All of the foregoing features reduce manufacturing time and costs, andprovide accessory manufacturers with the ability to provide covers for“next generation” devices as they are brought to market, therebyeliminating the delay time that often occurs between the introduction ofnew devices and the introduction of accessories for devices. All of theforegoing also may reduce consumer costs, by eliminating the need topurchase a new cover when purchasing a “next generation” device, andimproves customer satisfaction for “next generation” devices, becauseaccessories, particularly protective accessories, are available at thesame time.

Some embodiments comprise pre-assembled covers comprising medallionsaffixed to a film or an elastic fabric than can be stretched to conformto the shape of the device to be protected as well as embodiments inwhich the medallions are positioned and affixed to the device by theuser. By combining specific shapes, sizes, configurations, contours andorientations of the medallions, the protective covers can be designed toprotect specific, targeted areas of the device to be protected. Thesize, shape, thickness and composition of the medallions may be varied,depending on a number of factors including, but not limited to, thedesired effect, e.g., impact resistance, vibration dampening, and thelike. In addition, the configuration of the medallions may be varied,and more than one type of medallion shape may be used to provideprotection for a specific device.

The size, shape, configuration, orientation and dimensions of the pad,medallions, medallion contours, hinges, grooves and flange may be variedas desired in order to achieve the desired characteristics for themedallion design. However, it should be understood that in each of theforegoing embodiments, and in any medallion according to the presentdisclosure, all of the foregoing measurements can vary depending on thedesired characteristics and design of the medallion. For example, themedallion s are designed to provide a variety of characteristics suchas, but not limited to, cushioning, vibration dampening and/or impactabsorption, and the like. The characteristics of the medallion may bevaried by changing the thickness and/or material type of cushioninglayer in the medallions, changing the spacing between the medallions(e.g., the width of the channels), and/or changing the contours of themedallions, and the like. For example, using a gel for cushioning layerprovides a pad with cushioning and vibration dampening characteristics;using a foam decreases the weight of the pad; using a frothed foamincreases the impact absorption of the pad; etc. In general, increasingthe thickness of the cushioning layer in the medallions generallyincreases the foregoing characteristics; and using a combination ofmaterials for cushioning layer may provide a combination ofcharacteristics.

It should be noted that the terms “first,” “second,” and the like hereindo not denote any order or importance, but rather are used todistinguish one element from another, and the terms “a” and “an” hereindo not denote a limitation of quantity, but rather denote the presenceof at least one of the referenced items. Similarly, it is noted that theterms “bottom” and “top” are used herein, unless otherwise noted, merelyfor convenience of description, and are not limited to any one positionor spatial orientation. In addition, the modifier “about” used inconnection with a quantity is inclusive of the stated value and has themeaning dictated by the context (e.g., includes the degree of errorassociated with measurement of the particular quantity). Unless definedotherwise, technical and scientific terms used herein have the samemeaning as is commonly understood by one of skill in the art to whichthis disclosure belongs.

While the disclosure has been described with reference to an exemplaryembodiment, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of anyappended claims.

1. A cover for an electronic device, comprising: a flexible base sheethaving a thickness, the base sheet being adapted to stretch and conformto at least a portion of the outer surface of the device; and aplurality of spaced apart medallions having a thickness greater thanthat of the base sheet, the plurality of medallions extending outwardlyfrom the base sheet, to maintain the device in spaced relation from asurface.
 2. The cover of claim 1, wherein one of the medallions is ascreen bezel.
 3. The cover of claim 1, wherein the medallions comprisean perimeter flange.
 4. The cover of claim 1, further comprising apressure sensitive adhesive disposed between the medallions and the basesheet.
 5. The cover of claim 1, further comprising a welded jointdisposed at an interface between the medallions and the base sheet. 6.The cover of claim 2, further comprising a screen cover that overlapsthe screen bezel.
 7. The cover of claim 6, wherein the bezel comprises aperimeter flange.